Helmet having a chin bar collar

ABSTRACT

A helmet comprising an outer shell and a chin bar collar is disclosed. The outer shell comprises an interior surface and an open front portion. The chin bar collar comprises a chin guard and a collar segment forming a continuous loop. The collar segment is coupled to the interior surface of the outer shell. A majority of the collar segment is positioned within an interior space of the outer shell, and a majority of the chin guard is positioned outside the interior space of the outer shell. The outer shell may include at least two coupling points, at least one on each side of the open front portion, coupling the chin bar collar to the outer shell. The helmet may include at least one bracket coupled to the interior surface of the outer shell. The chin bar collar may be releasably coupled to the interior surface of the outer shell.

RELATED APPLICATIONS

This application claims the benefit of U.S. provisional patent application 62/245,775, filed Oct. 23, 2015 titled “Helmet Having a Looped Chin Bar,” the entirety of the disclosure of which is hereby incorporated by this reference.

TECHNICAL FIELD

Aspects of this document relate generally to helmets with chin bars.

BACKGROUND

Protective headgear and helmets are used in a wide variety of sports, athletics, competitions, and activities. Some endeavors require more protection than others, especially activities involving high speeds in obstacle-filled environments, like downhill racing or off-road motorized vehicles. Many participants of such activities wear full-face helmets, meaning the helmet has a chin bar.

Many conventional helmets with chin bars employ a chin bar that is bolted or otherwise attached to the front of the helmet. Other helmets, such as those disclosed in U.S. patent application Ser. No. 14/642,287, titled “Enduro Mountain Biking Chin Bar”, employ a removable chin bar attached to the outside of a helmet.

Upon impact, chin bars will flex to absorb and redirect energy, protecting the wearer. In conventional helmets, the impact forces are mainly born by the couplings attaching the chin bar to the outside of the helmet, thus requiring the couplings to be robust, and often numerous. This can make the manufacture of such helmets more complicated and more expensive. Furthermore, in cases where the chin bar is designed to be removable by the wearer, each of those numerous, robust couplings may require additional mechanisms to be releasable. Finally, because conventional helmets rely on a number of discrete coupling points to bear the impact force, some types impacts are absorbed better than others; many conventional helmets have limited resistance to impacts that are not head-on.

SUMMARY

According to one aspect, a helmet includes an outer shell and a chin bar collar. The outer shell includes an interior surface adjacent a lower edge of the outer shell and defines an interior space within a volume defined by the outer shell. The outer shell also includes an open front portion. The chin bar collar includes a chin guard and a collar segment integral with the chin guard. The combination of the chin guard and the collar segment forms a continuous loop. The collar segment is coupled to the interior surface of the outer shell and has a majority of the collar segment within the interior space of the outer shell and a majority of the chin guard outside the interior space of the outer shell.

Particular embodiments may comprise one or more of the following features. The outer shell may include at least two coupling points on the interior surface of the outer shell, at least one of the coupling points on each side of the open front portion of the helmet. The chin bar collar may be coupled to the outer shell at the at least two coupling points. The helmet may also include at least one bracket coupled to the interior surface of the outer shell, the chin bar collar mated with the helmet between the interior surface and the at least one bracket. The chin bar collar may comprise a ledge at each of two interfaces of the chin guard and the collar segment, each ledge mated with a leading edge of the outer shell proximate the open front of the helmet. Additionally, the interior surface of the outer shell may comprise at least one of an upper lip and a lower lip, the chin bar collar seated against the at least one of the upper lip and the lower lip. The collar segment may be seated in a recess in the interior surface of the outer shell shaped complementary to the collar segment. The helmet may further comprise at least one inner shell contained within the interior space of the outer shell. A majority of the collar segment may be positioned between the interior surface of the outer shell and the inner shell. Furthermore, the collar segment may be seated in a recess in at least one of the inner shell and the interior surface of the outer shell, and the recess may be shaped complementary to the collar segment. Finally, the collar segment may be releasably coupled to the outer shell.

According to another aspect of the disclosure, a helmet includes an outer shell and a chin bar collar. The outer shell comprises an interior surface defining an interior space within the outer shell, and an open front portion. The chin bar collar includes a chin guard and a collar segment forming an annulus. The collar segment is secured to the interior surface of the outer shell at at least one coupling point on each side of the open front portion of the helmet and at least one other location on the outer shell proximate a rear portion of the outer shell. A majority of the collar segment is positioned within the interior space of the outer shell and a majority of the chin guard is positioned outside the interior space of the outer shell.

Aspects and applications of the disclosure presented here are described below in the drawings and detailed description. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. The inventors are fully aware that they can be their own lexicographers if desired. The inventors expressly elect, as their own lexicographers, to use only the plain and ordinary meaning of terms in the specification and claims unless they clearly state otherwise and then further, expressly set forth the “special” definition of that term and explain how it differs from the plain and ordinary meaning. Absent such clear statements of intent to apply a “special” definition, it is the inventors' intent and desire that the simple, plain and ordinary meaning to the terms be applied to the interpretation of the specification and claims.

The inventors are also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above.

Further, the inventors are fully informed of the standards and application of the special provisions of 35 U.S.C. §112, ¶. Thus, the use of the words “function,” “means” or “step” in the Detailed Description or Description of the Drawings or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. §112, ¶6, to define the invention. To the contrary, if the provisions of 35 U.S.C. §112, ¶6 are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for”, and will also recite the word “function” (i.e., will state “means for performing the function of [insert function]”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for performing the function of . . . ” or “step for performing the function of . . . ,” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventors not to invoke the provisions of 35 U.S.C. §112, ¶6. Moreover, even if the provisions of 35 U.S.C. §112, ¶6 are invoked to define the claimed aspects, it is intended that these aspects not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the disclosure, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function.

The foregoing and other aspects, features, and advantages will be apparent to those artisans of ordinary skill in the art from the DESCRIPTION and DRAWINGS, and from the CLAIMS.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will hereinafter be described in conjunction with the appended drawings, where like designations denote like elements, and:

FIG. 1 is a perspective exploded view of a helmet with a chin bar collar;

FIG. 2 is a perspective view of a helmet with a chin bar collar; and

FIG. 3 is a cross section view of a helmet with a chin bar collar.

DETAILED DESCRIPTION

This disclosure, its aspects and implementations, are not limited to the specific helmet or material types, or other system component examples, or methods disclosed herein. Many additional components, manufacturing and assembly procedures known in the art consistent with helmet manufacture are contemplated for use with particular implementations from this disclosure. Accordingly, for example, although particular implementations are disclosed, such implementations and implementing components may comprise any components, models, types, materials, versions, quantities, and/or the like as is known in the art for such systems and implementing components, consistent with the intended operation.

The word “exemplary,” “example,” or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” or as an “example” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity.

While this disclosure includes a number of embodiments in many different forms, there is shown in the drawings and will herein be described in detail particular embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems, and is not intended to limit the broad aspect of the disclosed concepts to the embodiments illustrated.

FIGS. 1 through 3 depict non-limiting embodiments of a helmet 100 having a chin bar collar 102 and an outer shell 104. The chin bar collar 102 includes a chin guard 108 and a collar segment 110 forming an annular chin bar collar 102. By attaching the chin bar collar 102 inside the helmet 100 near a bottom edge of the helmet 100, impact forces on the chin bar are transmitted to the helmet through not just the front of the helmet, but around the collar of the helmet 100, dissipating the forces differently than if the impact is absorbed only on the front edge of the helmet as with conventional helmet designs. Additionally, by mounting the chin bar collar 102 inside the helmet with the collar segment mounted near the entrance of the helmet and the collar 102 supported around the inside of the helmet, impact forces on the chin guard 108 deform the chin guard less than if the same chin guard 108 were connected just at the front of the helmet by relying on the structural strength of the helmet to maintain the protective shape of the chin guard 108, allowing for lighter weight materials to be used for the chin guard 108 but providing greater structural strength than other helmet configurations.

The outer shell 104 has an interior surface 106, an open front portion 112 (for a wearer's face), and a lower edge 116. The outer shell 104 also has two leading edges 124. In the context of the present description, a leading edge 124 of the outer shell 104 refers to at least a portion of an edge of the outer shell 104 that is also part of the boundary of the open front portion 112. In many embodiments, the leading edges 124 are also proximate the lower edge 116 of the outer shell 104.

As shown in FIGS. 1 and 2, the outer shell 104 also has a rear portion 300. In the context of the present description, a rear portion 300 of an outer shell 104 refers to a portion within the half of the outer shell 104 which includes at least a part of the lower edge 116 and is opposite the half of the outer shell 104 which contains the open front portion 112 in its entirety. In some embodiments, the rear portion 300 of an outer shell 104 may be thought of as the portion of the outer shell 104 proximate the base of a wearer's skull.

The chin bar collar 102 comprises a collar segment 110 and a chin guard 108, which together form a closed loop, or annulus. In some embodiments, the chin bar collar 102 may be formed as a single piece, while in other embodiments the chin bar collar 102 may be assembled from multiple pieces. As shown in FIG. 2, the chin bar collar 102 is coupled to the interior surface 106 of the outer shell 104. More specifically, a majority 200 of the collar segment 110 is within an interior space 114 of the outer shell 104, while a majority of the chin guard 108 is outside the interior space 114. In the context of the present description, an interior space 114 refers to a volume defined by the interior surface 106 of the outer shell 104 and edges of the outer shell 104, such as the lower edge 116.

A helmet, such as helmet 100 of FIGS. 1-3, is a form of protective gear designed to protect the head from injury. Some activities require more protection than others, especially activities involving high speeds, such as downhill racing or riding motorized vehicles. Helmets designed for such activities often have chin bars to protect the wearer's face. Conventional helmets with chin bars employ half or full loop chin bars which are attached to the outside of the helmet. Upon impact, chin bars will flex to absorb and redirect energy, protecting the wearer. In conventional helmets, the impact forces are mainly born by the couplings attaching the chin bar to the outside of the helmet.

Advantageously, placing a looped chin bar, such as chin bar collar 102, inside the outer shell 104 of a helmet 100 distributes impact forces across the interior surface 106 of the outer shell 104, rather than across a handful of attachment points on the outside of a conventional helmet. As the chin bar collar 102 bows under the force of an impact, the outer shell 104 provides support along the majority of the collar segment 110. Furthermore, the added support provided by the outer shell 104 to a chin bar collar 102 coupled to the interior surface 106 may allow the helmet 100 to better withstand impacts from the side than conventional helmets with half loop chin bars.

As shown in FIGS. 1 and 2, the chin bar collar 102 has a ledge 122 at each of the two interfaces, or intersections, of the chin guard 108 and the collar segment 110, according to various embodiments. These ledges are shaped such that they are mated with the leading edges 124 of the outer shell 104 when the chin bar collar 102 is coupled to the outer shell 104. In other embodiments, the ledges may be only partially mated with the leading edges 124, or only mated along portions of the leading edges. In some embodiments, a ledge 122 may be a continuous thickening of the chin guard 108 such that the exterior surface of the chin guard 108 is flush with the exterior surface of the outer shell 104. In other embodiments, a ledge 122 may be a protrusion in the exterior surface of the chin guard 108 that is mated with a leading edge 124. The ledges 122 may help to direct impact forces into the leading edges 124 of the outer shell 104.

As shown in the non-limiting examples of FIGS. 1 and 2, the chin bar collar 102 is coupled to the interior surface 106 of the outer shell 104 at a plurality of coupling points 118. According to various embodiments, a helmet 100 may have one, two, three, or more coupling points 118. In some embodiments, a coupling point 118 may include a fastener that couples the chin bar collar 102 at a specific location on the interior surface 106. Examples of such coupling points 118 include, but are not limited to, mated protrusions, buckles, moldings, snap fit couplings, and holes paired with fasteners such as screws, pins, rivets, bolts, and the like.

In other embodiments, a coupling point 118 may refer to a range of the collar segment 110 that is coupled to the interior surface 106 along the entire length, rather than at a discrete point. One example is the use of an adhesive along a range of the collar segment 110. Another example is a non-limiting embodiment of an upper lip 126 and a lower lip 128 which have captured the collar segment 110 along a range. The upper lip 126 and lower lip 128 will be discussed further with respect to FIG. 3.

In various embodiments, a coupling point 118 may be releasable, allowing a user to remove the chin bar collar 102 from the helmet 100 when it is not needed, increasing ventilation and decreasing helmet weight. In some embodiments, such a coupling may require the use of a tool, like a wrench, to decouple. In other embodiments, a releasable coupling point may be actuated without tools. Examples include, but are not limited to, magnets, buckles, clips, biased latches, and snaps.

Chin bars in conventional helmets are often attached to the outer shell at numerous locations, as those attachment points must bear impact forces exerted on the chin bar. A chin bar collar 102 coupled to the interior surface 106 of the outer shell 104 of a helmet 100 is bolstered by the outer shell 104, as previously discussed, reducing the needed number and/or strength of coupling points 118. Reducing the number of coupling points 118 is advantageous, as it may simplify the manufacturing of the helmet 100. Furthermore, in embodiments where the chin bar collar 102 is releasably coupled to the interior surface 106, fewer coupling points 118 may mean easier operation.

FIGS. 1 and 2 show non-limiting examples of a helmet 100 having two coupling points 118 proximate the open front portion 112, and a third coupling point 118 at the rear portion 300 of the outer shell 104. In some embodiments, all coupling points 118 may be of the same type. In other embodiments, like the examples shown in FIGS. 1 through 3, the coupling points 118 may be of various types. As shown, the coupling point 118 at the rear portion 300 comprises an optional fastener coupling the collar segment 110 to the interior surface 106. The two coupling points 118 near the open front portion 112 each comprise a bracket 120. In other embodiments, the coupling point 118 at the rear portion 300 may merely be implemented as a ridge or track into which the collar segment 110 seats, as explained more below.

In one or more embodiments, a bracket 120 secures (e.g. limits the movement of or supports) at least one surface of the collar segment 110 of a chin bar collar 102 to the interior surface 106 of the outer shell 104. The bracket 120 itself is coupled to the interior surface 106 of the outer shell 104. In more particular embodiments, such as the non-limiting embodiments depicted in FIGS. 1 and 2, a bracket 120 secures the top edge and interior surface (i.e. surface of the chin bar collar 102 that faces the wearer) of the collar segment 110. In other embodiments, a bracket 120 may secure the bottom edge and interior surface of a collar segment 110. In still other embodiments, a bracket 120 may secure all surfaces of a collar segment 110 that are not facing the interior surface 106 of an outer shell 104.

In some embodiments, including the non-limiting embodiments shown in FIGS. 1 and 2, a bracket 120 may be mated with the collar segment 110, which may provide greater stability. In other embodiments, a bracket 120 may be proximate to, but not mated with, the collar segment 110, which may facilitate manufacturing. Furthermore, as shown in FIGS. 1 and 2, a bracket 120 may comprise a fastener, such as a pin or a screw, to further secure the collar segment 110, according to some, but not all, embodiments.

The brackets 120 are coupled to the interior surface 106 of the outer shell 104. In some embodiments, a bracket 120 may be formed as a part of the outer shell 104. For example, an outer shell 104 and one or more brackets 120 may be created together as a single piece of material through injection molding, or other techniques known in the art. In other embodiments, a bracket 120 may be coupled to the outer shell 104 after creation, whether directly attached to the interior surface 106, or coupled through some other material or object.

In various embodiments, the interior surface 106 of the outer shell 104 of a helmet 100 may be shaped to further secure the collar segment 110 of the chin bar collar 102. For example, some embodiments, including the non-limiting examples shown in FIGS. 1 through 3, may include an upper lip 126 and a lower lip 128. In some embodiments, the collar segment 110 is seated against these lips, the upper edge of the collar segment 110 seated against the upper lip 126 and the lower edge seated against the lower lip 128. In other embodiments, the lips may be proximate to, but not seated against, the collar segment 110. In still other embodiments, the inner surface 106 may have only one lip.

In some embodiments, including the non-limiting examples shown in FIGS. 1-3, a lip secures an edge of the collar segment 110 without constraining or overlapping with other surfaces of the collar segment 110. In other embodiments, a lip may wrap around the collar segment 110 to some degree, beyond the edge it secures, to secure the interior surface of the collar segment 110. As an option, the portion of a lip that wraps around to the interior surface of the collar segment 110 may be sized and shaped such that the chin bar collar 102 may be “snapped in”. In other words, pushing the collar segment 110 against such lips would cause them to deflect, receive the collar segment 110, and then snap back to capture the collar segment 110. Such a coupling would be of little use in a conventional helmet; however, with the additional strength and reduced fastening needs of a helmet 100 with a chin bar collar 102 inside, the use of such lips may help keep the chin bar collar 102 in place inside the helmet 100 during an impact event.

Helmets are often constructed with more than one shell or layer. For example, some helmets have a hard outer shell made of a durable material that wears well, and a softer inner shell made of energy absorbing materials. The non-limiting embodiments of a helmet 100 with a chin bar collar 102 shown in FIGS. 1 and 2 only depict an outer shell 104. It should be clear that these embodiments, and others discussed herein, may be adapted for use with one or more additional shells inside the outer shell 104, such that the chin bar collar 102 rests between the outer shell 104 and one or more interior shells. See, for example, FIG. 3. FIG. 3 shows a cross section view of the non-limiting embodiment of FIG. 2, cut on plane A. FIG. 3 includes an inner shell 400, not shown in FIG. 2. As shown, the collar segment 110 is between the outer shell 104 and the inner shell 400, and is also seated against an upper lip 126 and a lower lip 128.

Many of the features described with respect to the interior surface 106 of an outer shell 104 may also be implemented with an inner shell 400, according to various embodiments. For example, in one embodiment, the inner shell 400 may comprise a lower lip 128 against which the collar segment 110 is seated.

In various embodiments, an inner shell 400 and/or the interior surface 106 of an outer shell may be recessed, such that the collar segment 110 may be seated within. See, for example, the non-limiting example shown in FIG. 3, where the inner shell 400 has a recess 402 in which the collar segment 110 is seated. In some embodiments, only one shell is recessed. In other embodiments, shells on both sides of the collar segment 110 are recessed.

The helmets described herein may include any shells, layers, energy management material, and the like known in the art for helmets. The chin bar collar may comprise any materials known in the art for chin bars. In some embodiments, the chin bar collar 102 may be formed as a single piece of material. In other embodiments, the chin bar collar 102 may include additional parts for use in conjunction with coupling points 118 and the like. The coupling points 118, brackets 120, and lips may comprise any materials known in the art for helmets and helmet fasteners.

Where the above examples, embodiments and implementations reference examples, it should be understood by those of ordinary skill in the art that other helmet and manufacturing devices and examples could be intermixed or substituted with those provided. In places where the description above refers to particular embodiments of helmets, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these embodiments and implementations may be applied to other to helmet technologies as well. Accordingly, the disclosed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the disclosure and the knowledge of one of ordinary skill in the art. 

What is claimed is:
 1. A helmet, comprising: an outer shell, the outer shell comprising an interior surface adjacent a lower edge of the outer shell and defining an interior space within a volume defined by the outer shell, the outer shell comprising an open front portion; and a chin bar collar comprising a chin guard and a collar segment integral with the chin guard, the combination of the chin guard and the collar segment forming a continuous loop, the collar segment coupled to the interior surface of the outer shell and having a majority of the collar segment within the interior space of the outer shell and a majority of the chin guard outside the interior space of the outer shell.
 2. The helmet of claim 1, the outer shell further comprising at least two coupling points on the interior surface of the outer shell, at least one of the at least two coupling points on each side of the open front portion of the helmet, the chin bar collar coupled to the outer shell at the at least two coupling points.
 3. The helmet of claim 1, further comprising at least one bracket coupled to the interior surface of the outer shell, the chin bar collar mated with the helmet between the interior surface and the at least one bracket.
 4. The helmet of claim 1, wherein the chin bar collar comprises a ledge at each of two interfaces of the chin guard and the collar segment, each ledge mated with a leading edge of the outer shell proximate the open front of the helmet.
 5. The helmet of claim 1, wherein the interior surface of the outer shell comprises at least one of an upper lip and a lower lip, the chin bar collar seated against the at least one of the upper lip and the lower lip.
 6. The helmet of claim 1, wherein the collar segment is seated in a recess in the interior surface of the outer shell shaped complementary to the collar segment.
 7. The helmet of claim 1, further comprising at least one inner shell contained within the interior space of the outer shell, wherein a majority of the collar segment is positioned between the interior surface of the outer shell and the inner shell.
 8. The helmet of claim 7, wherein the collar segment is seated in a recess in at least one of the inner shell and the interior surface of the outer shell, the recess shaped complementary to the collar segment
 9. The helmet of claim 1, wherein the collar segment is releasably coupled to the outer shell.
 10. A helmet, comprising: an outer shell, the outer shell comprising an interior surface defining an interior space within the outer shell, the outer shell comprising an open front portion; and a chin bar collar comprising a chin guard and a collar segment forming an annulus, the collar segment secured to the interior surface of the outer shell at at least one coupling point on each side of the open front portion of the helmet and at least one other location on the outer shell proximate a rear portion of the outer shell; wherein a majority of the collar segment is positioned within the interior space of the outer shell and a majority of the chin guard is positioned outside the interior space of the outer shell.
 11. The helmet of claim 10, further comprising at least one bracket coupled to the interior surface of the outer shell, the chin bar collar mated with the helmet between the interior surface and the at least one bracket.
 12. The helmet of claim 10, wherein the chin bar collar comprises a ledge at each of two interfaces of the chin guard and the collar segment, each ledge mated with a leading edge of the outer shell proximate the open front of the helmet.
 13. The helmet of claim 10, wherein the interior surface of the outer shell comprises at least one of an upper lip and a lower lip, the chin bar collar seated against the at least one of the upper lip and the lower lip.
 14. The helmet of claim 10, wherein the collar segment is seated in a recess in the interior surface of the outer shell shaped complementary to the collar segment.
 15. The helmet of claim 10, further comprising at least one inner shell contained within the interior space of the outer shell, wherein a majority of the collar segment is positioned between the interior surface of the outer shell and the inner shell.
 16. The helmet of claim 15, wherein the collar segment is seated in a recess in at least one of the inner shell and the interior surface of the outer shell, the recess shaped complementary to the collar segment
 17. The helmet of claim 10, wherein the collar segment is releasably coupled to the interior surface of the outer shell. 